Didn’t get much done today, just worked on one end cap. I had thought about making a mock-up from door skin or cardboard but instead I went ahead mocking up with aluminum (1/4″ for top and bottom, 3/16″ for the face plate).
The 3/16″ face plate (vertical plate) was from a bit of scrap that was curved, large radius. I cut some 1/4″ plate for top and bottom and tacked them on. Then clamped the affair to the bumper.
It’s a trick transition, and you will see later that I still haven’t figured it out. I cut a bit of 1/4″ to fill the hole.
I couldn’t resist rough grinding a radius on the welds.
The corner filler bit is obvious in this pic.
I’m quite there yet, am I?
“if you can jump it, I can weld it”… ha!
I tacked the end cap to the bumper so that I could remove the clamp and took the bumper out to the van to see how it fit. Up until this point I was only guessing the dimensions of the end cap – I wanted it to end up about an inch behind my mudflaps and about 1/4″ from the body. Turned out I had to thin the endcap down a bit, was hitting the body.
So it was “MIller time!”! One tool that gets a lot of respect and care in use. Nasty bit of work but cuts the aluminum nicely. What’s with the rust on the blade? Must have got splashed with water, and we don’t put any oil or the like on tools that will be touching aluminum or stainless for fear of weld contamination.
Slimming things down.
I think it looks nicer than the first version.
And it fits to the van like I want it to.
I will have to zip cut the front of the endcap and re-form it to make the transition to the lower plate of the bumper. But I’m liking how things are going.